Government Polytechnic, Nanded
Production Engineering Department
Academic Year ( 2020-21)
PART A - PLAN
Micro Project Proposal
(For 1st to 6th Semester)
Micro Project Evaluation Sheet (I Scheme )
Name of Course and Code : Forming and joining process (22568)
Name Of Student: Tompe Vaibhav Raju Enrollment No. 1900200415
Name of Programme : PRODUCTION ENGG Semester : 5TH
Title of Micro Project : prepare a report on the application of various
welding joints.
Course Outcomes Achieved:- 1) Introduction to welding 2) Contents
3) Different Types, and Their Applications
1.Apply work study techniques to optimise production process.
ProcessAssessment ProductAssessment TotalMarks
PartAProjectPropo ProjectMethodolo PartB- IndividualPresenta
sal gy ProjectReport/Wor tion/Viva
kingModel (10)
(02Marks) (02Marks) (04Marks)
(02Marks)
Comments/Suggestions about team work/ leadership/Inter personal
communication
I work and got the more information / knowledge about the topic of prepare pp
on hot spinning and Sketch forming operation.
Any Other Comment i work got the more information / knowledge about the
topic of prepare pp on hot spinning and Sketch forming operation
Date : Signature
Name : Tompe Vaibhav Raju
Government Polytechnic, Nanded
Production Engineering Department
Academic Year ( 2020-21)
PART A - PLAN
Micro Project Proposal
(For 1st to 6th Semester)
Designation
Title of Micro-project:--Prepare ppt on design of hand lever
1.Brief Introduction : --
Welding :-
Welding is a fabrication process whereby two or more parts are
fused together by means of heat, pressure or both forming a join as
the parts cool. Welding is usually used on metals and
thermoplastics but can also be used on wood. The
completed welded joint may be referred to as a weldment.
Some materials require the use of specific processes and
techniques. A number are considered 'unweldable,' a term not
usually found in dictionaries but useful and descriptive in
engineering.
The parts that are joined are known as a parent material. The
material added to help form the join is called filler or consumable.
The form of these materials may see them referred to as parent
plate or pipe, filler wire, consumable electrode (for arc welding),
etc.
The completed welded joint may be referred to as a weldment.
Contents:
1. How does welding work?
2. Common joint configurations
3. Types of welding joints
4. Energy sources
5. Different types and what they are used for
6. Services
7. Where it is used?
Government Polytechnic, Nanded
Production Engineering Department
Academic Year ( 2020-21)
PART A - PLAN
Micro Project Proposal
(For 1st to 6th Semester)
How Does Welding Work?
Joining Metals
As opposed to brazing and soldering, which do not melt the base metal, welding
is a high heat process which melts the base material. Typically with the addition
of a filler material.
Heat at a high temperature causes a weld pool of molten material which cools to
form the join, which can be stronger than the parent metal. Pressure can also be
used to produce a weld, either alongside the heat or by itself.
Joining Plastics
Plastics welding also uses heat to join the materials (although not in the case of
solvent welding) and is achieved in three stages.
Firstly, the surfaces are prepared before heat and pressure is applied and,
finally, the materials are allowed to cool to create fusion. Joining methods for
plastics can be separated into external or internal heating methods, depending
on the exact process used.
Joining Wood
Wood welding uses heat generated from friction to join the materials. The
materials to be joined are subjected to a great deal of pressure before a linear
friction movement creates heat to bond the workpieces together.
This is a fast process which allows wood to be joined without adhesives or nails
in a matter of seconds.
Common Joint Configurations
Butt Joint
Government Polytechnic, Nanded
Production Engineering Department
Academic Year ( 2020-21)
PART A - PLAN
Micro Project Proposal
(For 1st to 6th Semester)
A connection between the ends or edges of two parts making an angle to one
another of 135-180° inclusive in the region of the joint.
T Joint
A connection between the end or edge of one part and the face of the other part,
the parts making an angle to one another of more than 5 up to and including 90°
in the region of the joint.
Corner Joint
A connection between the ends or edges of two parts making an angle to one
another of more than 30 but less than 135° in the region of the joint.
Edge Joint
A connection between the edges of two parts making an angle to one another of
0 to 30° inclusive in the region of the joint.
Lap Joint
Government Polytechnic, Nanded
Production Engineering Department
Academic Year ( 2020-21)
PART A - PLAN
Micro Project Proposal
(For 1st to 6th Semester)
A connection between two overlapping parts making an angle to one another of
0-5° inclusive in the region of the weld or welds.
Cruciform Joint
A connection in which two flat plates or two bars are welded to another flat
plate at right angles and on the same axis.
Types of Welding Joints
Welds Based on Configuration
Slot weld
Government Polytechnic, Nanded
Production Engineering Department
Academic Year ( 2020-21)
PART A - PLAN
Micro Project Proposal
(For 1st to 6th Semester)
Joint between two overlapping components made by depositing a fillet weld
around the periphery of a hole in one component so as to join it to the surface of
the other component exposed through the hole.
Plug weld
Weld made by filling a hole in one component of a workpiece with filler metal
so as to join it to the surface of an overlapping component exposed through the
hole (the hole can be circular or oval).
Based on Penetration
Partial penetration weld
Weld in which the fusion penetration is intentionally less than full penetration.
In the US the preferred term is partial joint penetration weld (PJP).
Full penetration weld
Welded joint where the weld metal fully penetrates the joint with complete root
fusion. In US the preferred term is complete joint penetration weld (CJP, see
AWS D1.1).
Government Polytechnic, Nanded
Production Engineering Department
Academic Year ( 2020-21)
PART A - PLAN
Micro Project Proposal
(For 1st to 6th Semester)
Welds Based on Accessibility
Features of Completed Welds
Butt weld
Government Polytechnic, Nanded
Production Engineering Department
Academic Year ( 2020-21)
PART A - PLAN
Micro Project Proposal
(For 1st to 6th Semester)
Fillet weld
Parent Metal
Metal to be joined or surfaced by welding, braze welding or brazing.
Filler Metal
Metal added during welding, braze welding, brazing or surfacing.
Weld Metal
All metal melted during the making of a weld and retained in the weld.
Heat Affected Zone (HAZ)
The part of the parent metal metallurgically affected by the weld or thermal
cutting heat, but not melted.
Fusion Line
Boundary between the weld metal and the HAZ in a fusion weld. This is a non-
standard term for weld junction.
Government Polytechnic, Nanded
Production Engineering Department
Academic Year ( 2020-21)
PART A - PLAN
Micro Project Proposal
(For 1st to 6th Semester)
Weld Root
Zone on the side of the first run furthest from the welder.
Weld Zone
Zone containing the weld metal and the HAZ.
Weld Face
The surface of a fusion weld exposed on the side from which the weld has been
made.
Weld Toe
Boundary between a weld face and the parent metal or between runs. This is a
very important feature of a weld since toes are points of high stress
concentration and often they are initiation points for different types of cracks
(eg fatigue cracks, cold cracks).
In order to reduce the stress concentration, toes must blend smoothly into the
parent metal surface.
Excess Weld Metal
Weld metal lying outside the plane joining the toes. Other non-standard terms
for this feature: reinforcement, overfill.
In fact, the thickness considered when designing a welded component is the
design throat thickness, which does not include the excess weld metal.
Government Polytechnic, Nanded
Production Engineering Department
Academic Year ( 2020-21)
PART A - PLAN
Micro Project Proposal
(For 1st to 6th Semester)
Run (pass)
The metal melted or deposited during one passage of an electrode, torch or
blowpipe.
Layer
Stratum of weld metal consisting of one or more runs.
Energy Sources
Different processes are determined by the energy source used, with a variety of
different techniques available.
Until the end of the 19th century, forge welding was the only method used, but
later processes, such as arc welding, have since been developed. Modern
methods use gas flame, electric arc, lasers, electron beam, friction and even
ultrasound to join materials.
Care needs to be taken with these processes as they can lead to burns, electric
shock, damaged vision, exposure to radiation or inhaling of poisonous welding
fumes and gases.
What are the Different Welding Types and What are They Used for?
There are a variety of different processes with their own techniques and
applications for industry, these include:
Arc
This category includes a number of common manual, semi-automatic and
automatic processes. These include metal inert gas (MIG) welding, stick
Government Polytechnic, Nanded
Production Engineering Department
Academic Year ( 2020-21)
PART A - PLAN
Micro Project Proposal
(For 1st to 6th Semester)
welding, tungsten inert gas (TIG) welding also know as gas tungsten arc
welding (GTAW), gas welding, metal active gas (MAG) welding, flux cored arc
welding (FCAW), gas metal arc welding (GMAW), submerged arc welding
(SAW), shielded metal arc welding (SMAW) and plasma arc welding.
These techniques usually use a filler material and are primarily used for joining
metals including stainless steel, aluminium, nickel and copper alloys, cobalt and
titanium. Arc welding processes are widely used across industries such as oil
and gas, power, aerospace, automotive, and more.
Friction
Friction welding techniques join materials using mechanical friction. This can
be performed in a variety of ways on different welding materials including steel,
aluminium or even wood.
The mechanical friction generates heat which softens the materials which mix to
create a bond as they cool. The manner in which the joining occurs is dependant
on the exact process used, for example, friction stir welding (FSW), friction stir
spot welding (FSSW), linear friction welding (LFW) and rotary friction welding
(RFW).
Friction welding doesn't require the use of filler metals, flux or shielding gas.
Friction is frequently used in aerospace applications as it is ideal for joining
otherwise 'non-weldable' light-weight aluminium alloys.
Friction processes are used across industry and are also being explored as a
method to bond wood without the use of adhesives or nails.
Electron Beam
This fusion joining process uses a beam of high velocity electrons to join
materials. The kinetic energy of the electrons transforms into heat upon impact
with the workpieces causing the materials to melt together. Electron beam
welding (EBW) is performed in a vacuum (with the use of a vacuum chamber)
to prevent the beam from dissipating
Government Polytechnic, Nanded
Production Engineering Department
Academic Year ( 2020-21)
PART A - PLAN
Micro Project Proposal
(For 1st to 6th Semester)
There are many common applications for EBW, as can be used to join thick
sections. This means it can be applied across a number of industries from
aerospace to nuclear power and automotive to rail.
Laser
Used to join thermoplastics or pieces of metal, this process uses a laser to
provide a concentrated heat ideal for barrow, deep welds and high joining rates.
Being easily automated, the high welding speed at which this process can be
performed makes it perfect for high volume applications, such as within the
automotive industry.Laser beam welding can be performed in air rather than in
a vacuum such as with electron beam joining.
Resistance
This is a fast process which is commonly used in the automotive industry. This
process can be split into two types, resistance spot welding and resistance seam
welding.Spot welding uses heat delivered between two electrodes which is
applied to a small area as the workpieces are clamped together.Seam welding is
similar to spot welding except it replaces the electrodes with rotating wheels to
deliver a continuous leak-free weld.
Services
TWI has one of the most definitive ranges of services.
Welding Joints: Different Types, and Their Applications
Welding joints are very frequently used for long lasting welding.
Nowadays there has been great progress in welding technology; it has
secured a major place within modern machine components. There are
several advantages of welding joints like higher efficiency, lightweight,
smooth appearance, not expensive, flexibility for alteration as well as
addition, and Join process is possible in difficult locations through
welding. Due to these benefits, the welding process is suitable for
combining the components in modern machines., crankshafts, pulleys,
large gears, flywheels, machine frames, gear housing, mill-stands, and
bases.
Government Polytechnic, Nanded
Production Engineering Department
Academic Year ( 2020-21)
PART A - PLAN
Micro Project Proposal
(For 1st to 6th Semester)
What are Welding Joints?
The welding joints are edges otherwise points where different metal or plastic pieces are connected
together. These can be formed by connecting various metals otherwise plastic pieces based on an
exact geometry. There are different types of joints are available in the market but as per Welding
Society in America has classified some of them like butt, edge, corner, tee, and lap. These joints
may have different designs at the joint wherever actual welding can take place.
Welding Joints
Before the welding procedure is happening then the preparation of joints is
required. There are different types of joint techniques are available
which include routing, stamping, shearing, casting, forging machining,
filing, plasma arc cutting, oxyacetylene cutting, and grinding.
Different Types of Welding Joints
The welding joints are classified into five types for welding two parts as
one. The welding joints are butt, corner, lap, tee, & edge joint.
1) Butt Joint
The butt joint can be formed by arranging the two metal ends
together are named as a butt joint. In this kind of joint, the two ends
lie on top of the similar plane otherwise side by side. This joint is
very useful in combining the metal or plastic parts jointly. Butt Joint
includes different types of welding namely Square Butt, Bevel
groove, V-groove weld, J-groove, U-groove, Flare-V-groove, Flare-
bevel-groove butt welding.
Government Polytechnic, Nanded
Production Engineering Department
Academic Year ( 2020-21)
PART A - PLAN
Micro Project Proposal
(For 1st to 6th Semester)
Butt Joint
The applications of Butt joint include Pipes Valves, Flanges, and Fittings
2) Corner Joint
The corner joint can be formed by arranging the corner of two metal
ends at the right angle is named as a corner joint. The L shape can be
formed by welding two parts with a corner joint. Corner joint includes
different types of welding namely Fillet, Spot, Square-groove, V-groove,
Bevel-groove, U-groove, J-groove, Flare-V-groove, and Edge Corner-
flange.
Corner Joint
The applications of Corner Joint include sheet metal, light sheets,
heavier metal sheets, and this jointing is also used in the designing of
boxes, frames & another same kind of fabrication.
3) T-Joint
Government Polytechnic, Nanded
Production Engineering Department
Academic Year ( 2020-21)
PART A - PLAN
Micro Project Proposal
(For 1st to 6th Semester)
The T-joint can be arranged by interconnecting two ends at 90-degree
angle as well as one element lies in the middle of the other. The two
ends are welded like a letter T, so it is named as T-joint. T-joint includes
different types of welding namely Fillet, Plug, Slot, Bevel-groove, J-
groove, Flare-bevel groove, and Melt-through weld.
T-Joint
The applications of T-joint mainly include when a metal part is connected
to some type of base, attaching thin plates, structural and machine
applications
4) Lap Joint
The lap joint can be formed whenever the two metal or plastic ends are
placed one above another and then joined through the welding process.
This type of joint may one-sided otherwise dual sided. Lap joints are
frequently used to weld two metal pieces with dissimilar width. Lap joint
includes different types of welding namely Fillet, Bevel-groove, J-groove,
Plug, Slot, Spot, Flare-bevel-groove
Lap Joint
The applications of lap joint mainly include gas tungsten arc weld,
resistance spot welding, as well as gas metal arc welding. These are
also used in plastic, wood, tabling, temporary framing, assembly of the
frame in cabinet making and in automation relating processes.
Government Polytechnic, Nanded
Production Engineering Department
Academic Year ( 2020-21)
PART A - PLAN
Micro Project Proposal
(For 1st to 6th Semester)
5) Edge Joint
The edge joint can be formed by connecting the two edges of metal
parts jointly are known as edge joint. Edge joint is mainly used wherever
the two sheet edges are nearby & that is estimated parallel planes by
the welding end. In this kind of joint, the join does not enter completely
due to the width of joint, thus it cannot be utilized within the applications
like stress as well as pressure. Edge joint includes different types of
welding namely Square-groove, Bevel-groove, V-groove, J-groove, U-
groove, Edge-flange, and Corner-flange weld.
Edge Joint
The applications of edge joint mainly include where sheets edges are
nearby and that are roughly parallel planes on the welding end. These
joints are applicable where the join is essential to weld two nearby
pieces jointly, and where the thickness of sheets is less than 3mm.
Benefits of Welding Over Riveting
The benefits of welding over riveting mainly include the following.
The welding process is mainly used to weld the metal edges
without having to overlap.
Welding method saves burden during the assembly process.
Welded joints are superior several times due to the material lying
on both sides of the join which is physically joined.
Welding process can simply join sections of pipe otherwise metalcolumn.
Government Polytechnic, Nanded
Production Engineering Department
Academic Year ( 2020-21)
PART A - PLAN
Micro Project Proposal
(For 1st to 6th Semester)
Thus, this is all about different types of welding joints. From the
above information finally, we can conclude that why these joints
are necessary for various applications. Some of them are used
in lightweight as well as heavy metals. Some types of welding
joints can generate strong welds, therefore, they are difficult
whereas others are inexpensive and generate soft welds. Each
welding joint has its own advantages, disadvantages, and
applications.
WHAT IS WELDING? - DEFINITION, PROCESSES AND TYPES OF
WELDS
HHHJHGOWHAT IS WELDING? - DEFINITION, PROCESSES AND
TYPES OF WELDS
WHAT IS WELDING? - DEFINITION, PROCESSES AND TYPES OF
WELDS
WHAT IS WELDING? - DEFIN WHAT IS WELDING? - DEFINITION,
PROCESSES AND TYPES OF WELDS
WHAT IS WELDING? - DEFINITION, PROCESSES AND TYPES OF
WELD
Government Polytechnic, Nanded
Production Engineering Department
Academic Year ( 2020-21)
PART A - PLAN
Micro Project Proposal
(For 1st to 6th Semester)
Splan
S. Details of activity Planned Planned Name of responsible
No start finish team members
. date Date
1. Selection of topic, collect the information Maroti Khaire
about topic, fill the given format.Search
information & other remaining work.
6. skill developed / learning outcomes of this micro project :-
We got the knowledge about the Sketch forming operation
Date of submission : Name and signature of the lecturer
